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Check the headlight fuse that's INSIDE the box. If an oversized fuse has been put in the fusebox you will have problems with the wire overheating whenever there is a problem in the circuit.

There is a short circuit (wire touching chassis ground) somewhere in the lighting circuit, but the wire is burning because an oversized fuse has been put in the circuit.

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Q: Why does the wire from the fuse box to the head light switch burn up?
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